2004 CHEVROLET OPTRA fuel cap

Seats and Restraint Systems........................... 1-1
Front Seats
............................................... 1-2
Rear Seats
............................................... 1-8
Safety Belts
.............................................1-10
Child Restraints
.......................................1-29
Air Bag Systems
......................................1-51
Restraint System Check
............................1-60
Features and Controls..................................... 2-1
Keys
........................................................ 2-2
Doors and Locks
....................................... 2-7
Windows
.................................................2-14
Theft-Deterrent Systems
............................2-16
Starting and Operating Your Vehicle
...........2-18
Mirrors
....................................................2-35
Storage Areas
.........................................2-37
Sunroof
..................................................2-39
Instrument Panel............................................. 3-1
Instrument Panel Overview
.......................... 3-2
Climate Controls
......................................3-19
Warning Lights, Gages, and Indicators
........3-24
Audio System(s)
.......................................3-40Driving Your Vehicle....................................... 4-1
Your Driving, the Road, and Your Vehicle
..... 4-2
Towing
...................................................4-31
Service and Appearance Care.......................... 5-1
Service
..................................................... 5-3
Fuel
......................................................... 5-5
Checking Things Under the Hood
...............5-10
Headlamp Aiming
.....................................5-44
Bulb Replacement
....................................5-44
Windshield Wiper Blade Replacement
.........5-50
Tires
......................................................5-51
Appearance Care
.....................................5-73
Vehicle Identification
.................................5-81
Electrical System
......................................5-82
Capacities and Specifications
.....................5-90
Normal Maintenance Replacement Parts
......5-91
Maintenance Schedule..................................... 6-1
Maintenance Schedule
................................ 6-2
Customer Assistance and Information.............. 7-1
Customer Assistance and Information
........... 7-2
Reporting Safety Defects
...........................7-11
Index................................................................ 1
2004 Chevrolet Optra Owner ManualM

This light will also come on during a malfunction in one
of two ways:
•Light Flashing— A misfire condition has been
detected. A misfire increases vehicle emissions
and may damage the emission control system on
your vehicle. Diagnosis and service may be
required.
•Light On Steady— An emission control system
malfunction has been detected on your vehicle.
Diagnosis and service may be required.
If the Light Is Flashing
The following may prevent more serious damage to
your vehicle:
•Reducing vehicle speed.
•Avoiding hard accelerations.
•Avoiding steep uphill grades.If the light stops flashing and remains on steady, see “If
the Light Is On Steady” following.
If the light continues to flash, when it is safe to do so,
stop the vehicle.Find a safe place to park your vehicle.
Turn the key off, wait at least 10 seconds and restart
the engine. If the light remains on steady, see “If
the Light Is On Steady” following. If the light is still
flashing, follow the previous steps, and see your dealer
for service as soon as possible.
If the Light Is On Steady
You also may be able to correct the emission system
malfunction by considering the following:
Did you recently put fuel into your vehicle?
If so, reinstall the fuel cap, making sure to fully install
the cap. SeeFilling Your Tank on page 5-7. The
diagnostic system can determine if the fuel cap has
been left off or improperly installed. A loose or missing
fuel cap will allow fuel to evaporate into the atmosphere.
A few driving trips with the cap properly installed
should turn the light off.
3-34

Fuel Gage
Your fuel gage tells you
about how much fuel you
have left when the
ignition is turned to ON.
When the tank nears empty, the low fuel warning light
will come on. You still have a little fuel left, but you
should get more soon. SeeLow Fuel Warning Light on
page 3-39for more information.
Here are four things that some owners ask about. None
of these show a problem with your fuel gage:
•At the service station, the gas pump shuts off
before the gage reads full.
•It takes a little more or less fuel to fill up than the
gage indicated. For example, the gage may have
indicated the tank was half full, but it actually took a
little more or less than half the tank’s capacity to
fill the tank.
•The indicator moves a little when you turn a corner
or speed up.
•The gage goes back to empty when you turn off the
ignition.
Low Fuel Warning Light
This light comes on when
the fuel tank is low on fuel.
The low fuel warning light comes on when there is
approximately 2.0 gallons (7.5 liters) of fuel remaining in
the tank.
To turn the light off, add fuel to the fuel tank. SeeFilling
Your Tank on page 5-7.
3-39

Certication Label
The Certification label, found either on the center pillar,
near the driver’s door latch or on the end of the
driver’s door, tells you the gross weight capacity of your
vehicle, called the Gross Vehicle Weight Rating
(GVWR). The GVWR includes the weight of the vehicle,
all occupants, fuel and cargo. Never exceed the
GVWR for your vehicle, or the Gross Axle Weight Rating
(GAWR) for either the front or rear axle.
And, if you do have a heavy load, you should spread it
out. Do not carry more than 123 lbs (56 kg) in your trunk.
{CAUTION:
Do not load your vehicle any heavier than the
GVWR, or either the maximum front or rear
GAWR. If you do, parts on your vehicle can
break, and it can change the way your vehicle
handles. These could cause you to lose
control and crash. Also, overloading can
shorten the life of your vehicle.
Notice:Overloading your vehicle may cause
damage. Repairs would not be covered by your
warranty. Do not overload your vehicle.
If you put things inside your vehicle — like suitcases,
tools, packages, or anything else — they will go as fast
as the vehicle goes. If you have to stop or turn
quickly, or if there is a crash, they will keep going.
4-36

Service............................................................5-3
Doing Your Own Service Work.........................5-4
Adding Equipment to the Outside of Your
Vehicle......................................................5-5
Fuel................................................................5-5
Gasoline Octane............................................5-5
Gasoline Specifications....................................5-5
California Fuel...............................................5-6
Additives.......................................................5-6
Fuels in Foreign Countries...............................5-7
Filling Your Tank............................................5-7
Filling a Portable Fuel Container.......................5-9
Checking Things Under the Hood....................5-10
Hood Release..............................................5-10
Engine Compartment Overview.......................5-12
Engine Oil...................................................5-14
Engine Air Cleaner/Filter................................5-18
Automatic Transaxle Fluid..............................5-20
Manual Transaxle Fluid..................................5-20
Hydraulic Clutch...........................................5-20
Engine Coolant.............................................5-21
Coolant Surge Tank Pressure Cap..................5-24
Engine Overheating.......................................5-24
Cooling System............................................5-27
Power Steering Fluid.....................................5-33Windshield Washer Fluid................................5-34
Brakes........................................................5-35
Battery........................................................5-38
Jump Starting...............................................5-39
Headlamp Aiming...........................................5-44
Bulb Replacement..........................................5-44
Halogen Bulbs..............................................5-44
Headlamps..................................................5-44
Front Turn Signal and Parking Lamps..............5-45
Turn Signal Lamps (Side)..............................5-46
Fog Lamps..................................................5-46
Sidemarker Lamps (Front)..............................5-47
Sidemarker Lamps (Rear)..............................5-47
Center High-Mounted Stoplamp (CHMSL).........5-48
Taillamps, Turn Signal, Stoplamps and
Back-up Lamps.........................................5-48
Replacement Bulbs.......................................5-49
Windshield Wiper Blade Replacement..............5-50
Tires..............................................................5-51
Inflation - Tire Pressure.................................5-57
Tire Inspection and Rotation...........................5-58
When It Is Time for New Tires.......................5-59
Buying New Tires.........................................5-60
Uniform Tire Quality Grading..........................5-60
Section 5 Service and Appearance Care
5-1

The tethered fuel cap is located behind a hinged door
on the passenger’s side of your vehicle.
To remove the fuel cap, turn it slowly to the left
(counterclockwise). The fuel cap has a spring in it. If
you let go of the cap too soon, it will spring back to
the right.
{CAUTION:
If you spill fuel and then something ignites it,
you could be badly burned. Fuel can spray out
on you if you open the fuel cap too quickly. This
spray can happen if your tank is nearly full, and
is more likely in hot weather. Open the fuel cap
slowly and wait for any “hiss” noise to stop.
Then unscrew the cap all the way.
Be careful not to spill fuel. Do not top off or overfill your
tank, and wait a few seconds after you have finished
pumping before you remove the nozzle. Clean fuel from
painted surfaces as soon as possible. SeeCleaning
the Outside of Your Vehicle on page 5-76.
5-8

When you put the fuel cap back on, turn it to the right
(clockwise) until you hear a clicking sound. Make
sure you fully install the cap. The diagnostic system can
determine if the fuel cap has been left off or improperly
installed. This would allow fuel to evaporate into the
atmosphere. SeeMalfunction Indicator Lamp on
page 3-33.
{CAUTION:
If a re starts while you are refueling, do not
remove the nozzle. Shut off the ow of fuel by
shutting off the pump or by notifying the
station attendant. Leave the area immediately.
Notice:If you need a new fuel cap, be sure to get
the right type. Your dealer can get one for you.
If you get the wrong type, it may not t properly.
This may cause your malfunction indicator lamp to
light and may damage your fuel tank and emissions
system. SeeMalfunction Indicator Lamp on
page 3-33.
Filling a Portable Fuel Container
{CAUTION:
Never ll a portable fuel container while it is in
your vehicle. Static electricity discharge from
the container can ignite the gasoline vapor.
You can be badly burned and your vehicle
damaged if this occurs. To help avoid injury to
you and others:
Dispense gasoline only into approved
containers.
Do not ll a container while it is inside a
vehicle, in a vehicle’s trunk, pickup bed or
on any surface other than the ground.
Bring the ll nozzle in contact with the
inside of the ll opening before operating
the nozzle. Contact should be maintained
until the lling is complete.
Do not smoke while pumping gasoline.
5-9

Tire Terminology and Denitions
Air Pressure:The amount of air inside the tire pressing
outward on each square inch of the tire. Air pressure
is expressed in pounds per square inch (psi) or
kilopascal (kPa).
Accessory Weight:This means the combined weight
of optional accessories. Some examples of optional
accessories are, automatic transmission, power steering,
power brakes, power windows, power seats, and air
conditioning.
Aspect Ratio:The relationship of a tire’s height to
its width.
Belt:A rubber coated layer of cords that is located
between the plies and the tread. Cords may be made
from steel or other reinforcing materials.
Bead:The tire bead contains steel wires that hold the
tire onto the rim.
Bias Ply Tire:A pneumatic tire in which the plies are
laid at alternate angles, less than 90 degrees to the
centerline of the tread.
Cold Ination Pressure:The amount of air pressure in
a tire, measured in pounds per square inch (psi) or
kilopascal (kPa), before a tire has built up heat
from driving. SeeInflation - Tire Pressure on page 5-57.Curb Weight:This means the weight of a motor
vehicle with standard and optional equipment including
the maximum capacity of fuel, oil and coolant, but
without passengers and cargo.
DOT Markings:A code molded into the sidewall of a
tire signifying that the tire is in compliance with the U.S.
Department of Transportation motor vehicle safety
standards. The DOT code includes the Tire Identification
Number (TIN), an alphanumeric designator which can
also identify the tire manufacturer, production plant,
brand and date of production.
GVWR:Gross Vehicle Weight Rating, seeLoading
Your Vehicle on page 4-33.
GAWR FRT:Gross Axle Weight Rating for the front
axle, seeLoading Your Vehicle on page 4-33.
GAWR RR:Gross Axle Weight Rating for the rear axle,
seeLoading Your Vehicle on page 4-33.
Intended Outboard Sidewall:The side of an
asymmetrical tire that must always face outward when
mounted on a vehicle.
Kilopascal (kPa):The metric unit for air pressure.
There are 6.9 kPa’s to one psi.
Light Truck (LT-Metric) Tire:A tire used on light duty
trucks and some multipurpose passenger vehicles.
5-55